Breathable Mattress Construction with Anti-Insect Attributes

ABSTRACT

Mattress constructions wherein the mattress construction has at least one breathable strip in the make-up thereof to allow air circulation to the core thereof and wherein the said strip may or may not be treated with an insecticide to deter insect infestation.

CROSS REFERENCE TO RELATED APPLICATION

This non-provisional patent application claims the benefit of U.S. Provisional Patent Application No. 62/129,192 filed Mar. 6, 2015, entitled Breathable Mattress Construction with Anti-Insect Attributes, which application is incorporated in its entirety by this reference.

TECHNICAL FIELD

This invention relates to mattress constructions particularly with regard to moisture dissipation of the mattress core and to a means of preventing bug infestation of the mattress.

BACKGROUND ART

The current method in mattress construction is to allow airflow in a waterproof mattress by using a few 1 inch (approximate size) diameter metal vents on the sides of the mattress. Each vent has a number of holes for breathability but is extremely limited in the amount of airflow that is required to keep the mattress cavity or core free from moisture.

While sleeping, moisture vapor is given off by the human body transfers through the mattress ticking and into the mattress cavity or core. This is called: moisture vapor transference or MVT.

Once moisture vapor begins to build up inside the mattress cavity or core, it condenses, turning into water that causes a number of problems e.g. soaking into the padding causing shorter mattress life, growth of mold and possibly bacterial build up. Also, the use of metal vents with holes does not prevent bed bugs and dust mites from penetrating or passing through the holes in the metal vents which are about 5-6 mm in size, thereby infesting the mattress core.

Additionally, with the current onslaught of bed bugs infestation especially in multi habitant venues such as hotels, dormitories, student housing etc., it becomes imperative to take steps to prevent bug infestation.

Once infestation occurs it is difficult, if not impossible, to rid the infested mattresses short of expensive curative cleaning which is not always successful.

DISCLOSURE OF INVENTION

A disclosed method and construction are designed to allow increased airflow, prevention of moisture vapor build up and prevent insect penetration. Ideally air is allowed to pass in and out of a mattress that is made with an impervious/waterproof ticking (cover). One embodiment of this new and unique approach consists of using a narrow strip of breathable, liquid resistant mesh screen, that is impregnated with an EPA Registered Insecticide like DM50 and/or a naturally occurring insect repellent extract, such as geraniol, bifenthrin and combinations thereof and those in the pyrethroid family. The insecticide may also be topically applied to the mesh, which mesh, in one embodiment, is approximately one inch in width, around each of the four sides of the mattress, or where desired only around two sides of the mattress. The insect repellant may also be incorporated in the mesh itself during its fabrication process.

It should be understood that insects, such as bed bugs, have been known to build up resistance to some repellents, so those of ordinary skill in the art will recognize that from time to time, and depending upon the locale where the treated mattress will be used, the repellent composition will need to be reformulated to fit the circumstances.

By providing a way for air to enter and escape easily, removal of moisture vapor around the full perimeter (360 degrees) of the sides of the mattress is achieved and is a great improvement over current methods. The mesh can be attached into the mattress side seams by either Ultrasonic Welding Radio Frequency Welding or conventional sewing. The mesh is made from weaving polyester or nylon yarns so that the spaces created by weaving the finished mesh are approximately 0.05 to 0.5 millimeters in size, and in any event no more than about 0.1 millimeter to keep out bed bugs, their eggs and dust mites and their eggs.

In another embodiment of the invention, an approach is designed to reduce or eliminate a population of insects such as bed bugs and dust mites, involving either impregnating or topically applying a narrow strip of mesh screening (mesh 1-2 inches wide) with a EPA Registered Insecticide like DM50 and or a naturally occurring insect repellent extract such as geraniol. The mesh can be attached into the perimeter side panels of the mattress or one or both top and bottom edges of the mattress construction by either Ultrasonic Welding, Radio Frequency Welding, or stitching. As indicated, the repellant may also be incorporated in the mesh composition itself.

Once the mesh is secured into the seams or side panels of the mattress, it serves multiple functions. One, it allows the mattress to breath, meaning, a high volume of air can flow more easily in and out of the mattress, which allows a high volume of moisture vapor to escape. Two, it serves as a way to eliminate bed bug or dust mites from getting into the core of the mattress.

By either “impregnating” or topically applying” we mean that the repellent is either mixed with a coating material like urethane, that is then applied to the surface of the mesh or the repellent is incorporated in or is applied directly to the surface of the urethane after it has been cured.

The repellent then becomes an integral part of the urethane that is used to create a water repellant surface on the mesh screening. This water repellant surface not only helps prevent liquids from entering the seams of the mattress but also allows air and moisture vapor molecules to easily pass through.

Also, as will be seen in the drawings, the mesh, in one embodiment, is welded into the fabric cover covering the mattress at the center seam of the side panels or on the top and bottom perimeter seams of the mattress.

In the mattress industry, the sewing of the fabric tape or ribbon around the top and bottom perimeter seams, which is the most common way to manufacture mattresses, is also known as a “taped” edge.

Conventionally tape edge mattresses provide a natural hiding place for bed bugs and dust mites. The bugs manage to get themselves wedged between the tape/ribbon and the mattress fabric. “A natural hiding place for the bugs.” All of the mattresses of our invention are of a construction negating this effect, as will be seen.

In still another embodiment of the invention a mattress cover is sewn inside out with the mesh strip of the invention secured to the perimeter edges by means of stitching to thereby eliminate the mite and bug hiding places once the mattress cover is inverted or turned outside out for application to the mattress core.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 depicts one mattress construction comprising the prior art;

FIG. 2 is an enlarged view of the metal breathing fixture or ring illustrated in FIG. 1;

FIG. 3 depicts the current prior art means of sewing mattress covers leaving a turnable edge about the perimeter of the mattress;

FIG. 3a is an enlarged view of FIG. 3 taken along the line 3 a with a human thumb being shown for clarity;

FIG. 4 is a further illustration, like that shown in FIG. 3, showing how insects can seek shelter or hide under the mattress construction tape; or ribbon;

FIG. 4a is an enlarged view of FIG. 4 taken along the line 4 a;

FIG. 5 depicts one embodiment of our invention where an air breathing, insect treated mesh is secured about the perimeter (long and short sides) of the four side panels of the mattress;

FIG. 5a is an enlarged view of FIG. 5 taken along the line 5 a;

FIG. 6 depicts another embodiment of the mattress of our invention, wherein only one long side and one short side of the cover is provided with the mesh portion of the invention.

FIG. 7 shows the mesh portion shown in FIG. 6 and illustrating one type of fabrication thereof to the mattress cover;

FIG. 8 illustrates a segment of the mesh depicted in FIGS. 6 and 7 and showing more details of the construction thereof; and

FIG. 9 depicts an embodiment of our invention wherein the mesh portion is attached about the upper and lower edges of the mattress and/or cover.

BEST MODE FOR CARRYING OUT THE INVENTION

The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments.

However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention and the appended claims.

Referring now to the drawings wherein like numerals of reference depict like elements throughout, it will be seen that FIG. 1 depicts a conventional mattress 2 depicting a common means of venting the mattress core to the ambient atmosphere by means of spaced apertured ring fixtures 4.

FIG. 2 illustrates a segment of conventional mattress 2 having a typical circular, air breathing fixture 4 showing the limited number of apertures 6 that are available for delivering ambient air to the mattress 2 core.

Referring to FIGS. 3, 3 a, 4, and 4 a, the conventional method of mattress construction is shown where one type of mattress cover 8 is constructed with fabric side 10 secured by means of stitching 12 to upper edge or ribbon 14 thereby leaving an unsecured edge or flap 16 leaving spaces 18 wherein insects such as bed bugs would be drawn to because of the provided shelter construction of flap 16.

Referring to FIGS. 5 and 5 a, in this embodiment mattress 19 shows cover 20, shown in partial cutaway view, is constructed with intermediate mesh strip 22 circumscribing the perimeter of mattress cover 20. FIG. 6, illustrates the embodiment where mattress 23 has cover 21 having mesh strips 22 only on one side 25 and one end 27. Obviously the mesh strip 22 may be placed on two sides or alternately two ends of mattress 23, as may be desired.

In one embodiment, the cover 20 may be of fabric which is secured to the mesh strip 22 by means of stitching in an inside out fashion, and thereafter turned outside out in the other direction to thereby prevent exposure of any hiding places for insects such as is shown in FIGS. 3 and 4.

In other instances where the material of construction of the cover 20 is of synthetic material the polyester mesh strip 22 is secured by means of Ultra Sonic Welding or Radio Frequency Welding, thereby eliminating any gaps on spaces between the attaching members where insects could hide or gain access to the inner core of the mattress 19.

FIG. 7 is a partial view illustrating a non-stitching method of securing the mesh strip 22 to the bilateral material portions 24 of mattress cover 20, showing the apertures or holes 50 in enlarged size for clarity, it being understood that the strip 22 is woven and the exaggerated apertures or spaces 50 between threads is present throughout the strip 22 to allow ambient air therethrough.

The mesh strip 22, as more fully illustrated in FIG. 8, is of polyester construction which is achieved by weaving polyester or nylon yarns so that the apertures or spaces 50 formed by individual yarn threads making up said mesh are about 0.05 to 0.5 millimeters in size and in no event larger than 0.1 millimeters for best results. These apertures 50 allow for breathability of the mattress core to a much greater extent than the ring fixtures 4 with their limited number of apertures 6, while also preventing the entry of bed bugs and mites by reason of the small openings 50 through which bed bugs and mites cannot pass. Thus, in some instances, use of an insecticide or repellant is not needed where health or other concerns present themselves.

As indicated the mesh strip is of polyester and is attached to the mattress cover by 100% nylon thread. The stitches for attachment are fourteen lock stitches per linear inch. The lock stitch, as those of ordinary skill in the art will recognize, uses two threads that are tightly locked together by the mechanical action of a sewing machine that prevents the stitches from unraveling. Urethane coating on the mesh strip material, where desired, is about ⅛ ounce per square yard.

If the mesh strip is treated with insect deterrent, such as those described herein, the strip not only allows for “breathing” of the mattress but also acts to also ward off various insects including flies, mosquitoes, etc.

In some instances the mesh strip or edging may be color coded to indicate mattress size, enhance appearance or match an institution's colors, for example, where dormitory sized mattresses are used in college dormitories and the like.

As previously indicated, where anti bug attributes of the mattress of the invention are desired, the mesh strip is treated with an appropriate insecticide which is incorporated in its fabrication process of the mesh itself or has a repellant applied to the mesh after fabrication as by dipping, coating, etc., as is conventional in the coating of the materials art. One such insecticide is geraniol oil and its derivatives.

The mesh strip as indicated may be of various widths varying from ½ inch to 3 inches or more in width with 1-2 inches being found to be satisfactory. The thickness of the mesh may vary from about 3-15 mils, with about 5 mils being found to be preferable and being sufficiently thick to allow ease of handling and securing to the materials of construction making up the outer fabric or cover of the mattress. The mesh strip may be secured to the long or short sides of the cover, or both.

Referring now to FIG. 9 another embodiment of the invention is illustrated wherein in this instance, the mattress 30 has a web strip 32 secured about the upper and lower edges of mattress 30. As indicated hereinbefore, the web strip 32 (sometimes referred to in the trade as “ribbon”) may be stitched secured or electronically heat secured to the adjacent panels 34 and 36, thereby achieving breathability of the core of mattress 30. Obviously for mesh placement, only two of the side or end edges may be so configured as opposed to the entire perimeter. This also applies to using only one of the upper or lower edges, as opposed to both as shown.

As previously indicated for other embodiments, the mesh strip 32 may be treated with or have impermeated therein an anti bug insecticide. Obviously, where desired, the web strip 32 may be secured to one or both of the upper and lower edges of the mattress and/or cover.

EXAMPLE 1

As an example of a fabric mattress cover construction, a mattress cover top and bottom of navy oxford cloth having a cut size of 43″×87″×3 ¼″ has secured thereto by stitching, using the inverted method, a center seam venting mesh strip of 1 ¾″ width and a cut size of 233″. The mesh is of twill weave with 2/ply 150 denier/34 filaments—polyester warp; 3ply/150 denier/34 filaments—polyester filling with 22 picks per inch (PPI) and 88 warps.

The assembled cover is then applied to a mattress core of desired construction to thereby provide a breathable mattress which is impervious to bed bugs and mites.

The mesh may or may not be treated with an insecticide, but insecticide treatment is preferred depending upon desired outcomes.

EXAMPLE 2

A mattress cover is fabricated as set forth in Example 1. The mesh strip in this instance is impregnated with an insecticide, having as its active ingredients bifenthrin and acetamiprid. Obviously, any approved insecticide may be used in concentrations known to be safe for humans and animals. Ideally, the insecticide product is mixed with water such that the concentration is 1.25 ounces per one gallon of water to cover approximately 1,000 square feet of treated mesh. This also will vary from insecticide to insecticide.

EXAMPLE 3

A mattress is constructed having the following specifications:

Fabric for Mattress Cover:

Top & Bottom: 46″ Navy Oxford Cut Size: 43 × 87 × 3¼ Center Seam Venting: Mesh Cut Size: 233″ × 1¾ Fire Barrier: I-30 Fire Barrier Cut Size: 90″

Foam Core:

Size Foam Type Top: (Qty. = ½) 36 × 80 × 3¼ 1.8/35 Conv Bottom: (Qty. = ½) 36 × 80 × 3¼ 1.8/45 Conv Long Rails: (Qty. = 2) 2.5 × 80 × 3 1.8/55 Short Rails: (Qty. = 2) 31 × 4.5 × 3 1.8/55

Miscellaneous:

The mesh strip is as described herein and takes the configuration as depicted in FIG. 5.

EXAMPLE 4

A mattress is constructed having a conventional core, wherein a mesh strip or ribbon approximately 1 ¾ inch in width is secured about the upper and lower edges of a congruently configured cover. The mesh strip or ribbon is composed of polyester, which has the following specification:

-   -   Warp: These polyester yarns run parallel to the edges or         selvages of the mesh strip or ribbon.     -   Pick: These polyester yarns run perpendicular to the edges or         selvages of the mesh strip or ribbon.         As those in the art well know, the picks are woven over the         warps to form the woven article.

Such woven fabrics are commercially available, it only being necessary that the synthetic yarns be used, wherein spaces or apertures are no more than 0.1 millimeter in size.

The mesh strip or ribbon fabric is put through and submerged in a bath of insecticide fluid, as previously described, passed through nip rollers to remove excess insecticide fluid and run through a drying oven at approximately 250 degrees F., until dry. Thereafter, the mesh strip or ribbon has applied, thereto, in a process similar to that employed for the insecticide fluid application, a durable water repellant (DWR) which makes the fabric hydrophobic and is usually fluoropolymer based.

DWRs are conventionally known as those in the coating art will recognize, it only being necessary that DWR agents be used to obtain the desired end results, without. impinging upon the hole or aperture size of the mesh strip or ribbon to impede ambient air passage, therethrough.

Thus, the treated mesh strip or ribbon is secured to the cover components by means of sonic welding, but other methods as directed herein may be used as well.

The assembled mattress cover is then put in engaging association with the mattress core to thereby provide a breathable, insect repellant mattress.

The foregoing descriptions of the preferred embodiments of the invention have been presented only for the purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teachings. It is intended that the scope of the invention not be limited by the detailed descriptions, but by the claims and the equivalents to the claims appended hereto, and to those modifications that will make themselves apparent to those of ordinary skill in the art. 

What is claimed is:
 1. A mattress construction having at least one air permeable strip on one of the mattress sides to allow air circulation to the core thereof.
 2. A mattress construction having at least one air permeable strip having holes no more than 0.1 millimeter in size to allow air circulation to the core thereof wherein the strip has insecticide characteristics.
 3. In a mattress cover covering the mattress core, the improvement comprising: A synthetic material mesh strip having apertures no more than 0.1 millimeter in size wherein said strip makes up at least a portion of the lateral sides of said cover to allow ambient air to circulate into said mattress core.
 4. In a mattress cover adapted to cover a mattress core, the improvement consisting of: A mesh strip having apertures no more than 0.1 millimeter in size, wherein said strip makes up at least a portion of said cover whereby ambient air is allowed to pass therethrough.
 5. A mattress cover having long and short side portions attached to top and bottom portions adapted to fit over a mattress core wherein: At least one of said long and short side portions is provided with a mesh strip, said mesh strip being of a material having spaced apertures no more than 0.1 millimeter in size which allows ambient air to pass therethrough to said mattress core when said cover encompasses said mattress.
 6. The mattress cover in accordance with claim 5 wherein said mesh strip comprises woven synthetic yarn wherein the apertures or spaces between yarn threads are not more than 0.1 millimeter in size and said mesh is about 1-2 inches in width.
 7. The mattress cover in accordance with claim 6 wherein said mesh strip is treated with an insect repellant.
 8. A mattress cover in accordance with claim 4 wherein said mesh strip is incorporated in at least one of the upper and lower edge portions of said cover.
 9. The mattress cover in accordance with claim 8 wherein said mesh strip is treated with an insect repellant.
 10. A mattress with long and short sides and top and bottom having an inner core, a conformable mattress cover overlaying said inner core, a synthetic nylon mesh strip attached to and circumventing midway between top and bottom of the long and short sides wherein, said mesh strip has apertures no larger than 0.1 millimeter thereby allowing the passage of ambient air to said inner core.
 11. The mattress in accordance with claim 10 when said mesh strip is treated with an insect repellant. 